Switch electrolyte



Oct. 23, 1945. E 1 WILSON, JR 2,387,313

SW'ICH ELECTROLYTE Filed Feb. 7, 1944 Ftp.

l l l l l l l l l l l l l l l 48a +70 +60 +50 +40 fao +20 H0 0 -/o -20 -30 -40 -'a -60 -70 lNvENToR [.J. W/sa/V, JR.

Patented Oct. 23, 1945 UNITED STATES PATENT OFFICE (ci. zoo-15.2)

3 Claims.

This invention relates to switches and more particularly to electrically conducting mixtures useful in liquid level switches and the like.

Switches of this type ordinarily comprise a, receptacle partially filled with an electrically conducting medium, but having an air bubble disposed at the top of the receptacle for engagement with one or more electrodes according to the orientation of the receptacle. Tilting the receptacle causes the bubble to shift in the manner of a spirit level and exposes more or less of the electrode surface to the electrolyte. One form of such switch is used on aircraft instruments, specifically to control the erection of vertical gyroscopes. A number of electrodes are used, spaced about the cover of the switch receptacle, and the respective erecting devices are controlled by the differential current flow to the respective electrodes, as the bubble shifts in response to tilting of the device.

'I'he requirements of an ideal electrolyte are quite numerous and exacting, among which the following may be mentioned:

1) Because of the wide range of temperatures encountered in the normal use of aircraft, the electrolyte solution must remain liquid over a temperature range of 65 C. to+80 C. or even lsiligher with minimum viscosity and surface ten- (2) The conducting material, or dissolved salt must have a suflicient speciilc conductivity to convey the required amount of control current.

(3) 'I'he dissolved salt or the like must be used in such small quantities as not to increase the viscosity unduly or to crystallize out at low temperatures.

(4) The salt must be chemically stable in solution over the entire temperature range.

(5) The .solution must .not be corrosive on the switch or contacts.

(6) The electrolyte should have a relatively flat temperature coeillcient of resistance.

(7) I'he conductivity of the solution must not be too high or the air bubble may leave a conductive film on the contacts, decreasing the sharpness of the switching action.

All of the foregoing requirements have been satisfactorily met by the electrolyte herein described and claimed, and it is the principal object of this invention to provide an improved liquid level switch, and an electrolyte therefor satisfying the foregoing seven requirements. The invention is herein described as applied to a switch of the type appearing in my application, Serial No. 495,298, iiled July 19, 1943, jointly with John R. Mums and Robert Haskins, Jr.

In the drawing:

Fig. 1 is a vertical sectional view through one form of switch with which the electrolyte may be used; I

Fis. 2 is a cross-sectional view taken on the line 2--2 of Fig. l; and

Fig. 3 is a graph showing the conductivity of various electrolytes over a required temperature range.

The electrolyte consists principally of alcohol to satisfy the requirement for extreme fluidity over the range of from C. to +80 C. Although various alcohols and related solvents have been tried with varying degrees of success, the simpler aliphatic mono-hydroxy alcohols, such as ethanol and methanol, have been found most desirable. Ethanol boils at approximately 79 C. and is preferred for that reason to methanol, whose boiling point is appreciably lower, that is, 66 C. Other solvents having the power to enable ionization to take place, but with a vapor pressure as high as, or higher than, methanol, are less satisfactory for the reasonthat they develop unnecessarily high pressures within the switch by boiling at relatively low temperatures. Alcohols of lower vapor pressure, suchas propanol, have poor solubility characteristics and are relatively viscous, and hence do not provide good conductivity or a clean quick break in the current now when the electrode is uncovered.

Ethanol-water mixtures, comprising alcohol at 80% or greater concentration, have been used successfully. The nature of the solute is not critical provided that there is a reasonable compliance with the previously enumerated requirements. Because of their relative stability and non-corrosive action on the switch contacts, halogens of the alkali group have been used successfully. The iodldes are preferred over the chlorides and bromides, because of their higher solubilities and resulting higher conductivities. Sodium and potassium chlorides do not dissolve in sufficient concentrations to provide an appreciable current flow, butmay be used where current densities are small. Iodide of sodium has been found superior to the iodide of potassium and other metals of the alkali group, because of its relative cheapness, or because it has greater solubility. Sodium iodide satisfiesv all of the requirements of a desirable electrolyte, and appears superior to most of the other solutes tested.

It will be appreciated that salts having the general character of sodium iodide may be substituted to provide the necessary conductivity in the electrolyte. Magnesium chloride has been tried, but

has been found unstable at high temperatures, resulting in the formation of magnesium oxide and the liberation of hydrochloric acid. Of the various other solutes employed with success may be mentioned sodium and potassium thiocyanate, and trimethyl amine hydrochloride. All of the foregoing salts were employed in concentrations in the approximate range of from 0.1 N to 1.5 N solutions, and provided satisfactory results, in most instances. For the particular switch shown in Figs. 1 and 2, concentrations of approximately 0.3 N sodium iodide in ethanol worked very well. Adequate conductivity is provided ordinarily ir the salt is soluble to the extent of several percent in approinmately 80% alcohol at 65 C. Corrosion may be minimized if the metallic ions liberated by the salt are high in the electro-motive series, and if the metal forming the contacts is low in the series. As is apparent from Fig. 3, the electrolytes containing the most water and solute are the most conductive in the operating range above C. These solutions provide higher current concentrations with reduced heating in the switch.

A typical switch, as disclosed in Figs. 1 and 2, comprises a receptacle II preferably formed of a metallic cup I2 containing the electrolyte I3. An insulating cover Il preferably formed of glass or molded composition material hermetlcally closes the cup I2 to form a completely enclosed chamber, filled by the electrolyte except for an air bub ble I5. The cover Il is made with a concave inner surface forming a sloping roof for the cup I2, so that the bubble I 5 seeks the highest position in the manner of a spirit level. The cup I2 and cover Il may be sealed together by a ferrule II which may be rolled under an annular flange on the cup I2 as indicated in Fig. 1.

At least one, and preferably four or more electrodos n are molded directly in the cover u with contact surfaces exposed to the electrolyte I3.

'llhe electrodes I1 correspond to switch contacts and provide a path for current to flow from the ",jelectrolyte I3. Terminals or pins Il may prof lect from the electrodes I'I in the manner of radio ("1 tube socket connections, to provide means for "'lnountlng the unit and for conducting the current from the electrodes.

When a plurality of electrodes are used, they preferably are symmetrically disposed about the inner surface of the cover as illustrated in Fig. 2, so that the bubble I5, illustrated in broken lines, intercepts equal areas of each electrode when the receptacle is in the normal orlevel position. Current may be conducted to the electrolyte through the cup I2, as by means of terminal lug I9, and the current flows to each of the electrodes according to the resistance of the respective paths. The principal resistance in each path is provided by the reduced contact area at the exposed surface of each electrode as a result of the bubble I5 insulating a portion of each contact surface. Accordingly, when the receptacle is level, the bubble occupies a central space in the receptacle, and equal portions of all contact surfaces are covered by the bubble I 5, in which event` the same current flows through each electrode l1.

As the receptacle departs from the level position, the bubble moves toward the high side of the container, as it does in a spirit level, and at least one electrode I1 will have a larger surface exposed to the electrolyte and will receive a larger portion of the current than will the diametrally opposite electrode. Accordingly, the current dow from the respective electrodes is a lil asevera function of the position of the switch. The switch action provides a complete on and off action following a gradual variation in the current ow in the manner of a variable resistor. Bosses 2l may depend from the insulating cover I4 to guide the bubble in the general directions of the electrodes.

In a typical installation, the entire unit shown in Fig. 1 connects on the base of the rotor element of a vertica gyro. The current ilowing from the respective terminais I8 of opposite pairs of electrodes iiows through the respective field windings of a reversible erection motor serving to maintain the gyro in a verticai position against the action of drit. A typical illustration of this application of the invention is disclosed in application Serial No. 448,980 entitled Erecting means for gyro vertical instruments, filed June 29, 1942, by Robert S. Curry, Jr., and assigned to the assignee of the present invention.

Although the tendency is to use less concentrated alcohol in order to obtain greater conductivity, some undesirable effects may result from a solvent of this type. Experiments have shown that an electrolyte composed of sodium iodide in 80% ethanol behaves unstably if the current concentrations cause any appreciable heating. For example, a switch containing such an electrolyte properly may produce reduced current now through the partially insulated electrode immediately following a tilting of the switch such that the bubble covers a larger part of the electrode surface. Shortly thereafter, however, without change in the bubble position, the current might return to and even increase over the original normal density characterizing the level position. This erratic operation was investigated and the cause finally attributed to the evaporation of minute amounts of the alcohol from the film on the electrode exposed to the bubble. With alcohol at concentrations of it was coniectured that this evaporation into the bubble increased the perecentage of water in the illm and adjacent solvent, resulting in a substantial increase in the conductivity of the path through the nlm to the electrode even though the area contacted by the electrolyte was reduced. Acting on this hypothesis, azeotropic or constant boiling mixtures of ethanol and water were substituted, since these mixtures evaporate without changing the proportions of the residual solvent. No such further trouble was experienced and ample current concentrations were obtained even though the increased alcohol concentration resulted in a reduction of the ionization of the solute. 1n the case of ethanol, an azeotropic mixture comprises approximately a concentration; the nearer this concentration is observed, the more completely the foregoing erratic action is overcome.

It was felt at rst that a 95% concentration of ethanol would not ionize sufficiently with the salt to provide satisfactory conductivity, but this was found to be untrue. Even more unusually, it was found that in the low temperature portion of the range, higher specic conductivities were obtained with only 0.3 N iodide, than were obtained with electrolytes having larger percentages of water or solute. Although an electrolyteof 95% ethanol provides somewhat lower conductivity at the higher temperatures, that is. above 0 C., the overall effect is beneficial in that such an electrolyte has a much smaller temperature coefficient of resistivity and minimizes the temperature compensation requirements in the control clrcuit. This is clearly suggested in Fig. 3

wherein the curve comprising 0.3 N sodium receptacle containing an electrolyte, electrode iodide and 95% ethanol is the ilattest curve of means within said container having a surface the entire group of curves and, in fact, closely apadapted to contact said electrolyte to provide a proximates a straight line function. This concurrent-conducting path from said electrolyte to trasts with the remaining curves whose conduc- 5 Said electrode means, said electrolyte comprising tivity increases substantially as a power funcethanol and water containing an iodine of an tion of temperature. alkali metal at a concentration in the range Concentrations of ethanol in excess of 95% 0.1Nto 1.5 N.

may be used, though with a reduction in the 2. A variable electrical resistor effective over a ionzations obtainable. The 95% solutionisdesirl0 wide temperature range comprising a hermetiable additionally because it is quite readily obcally-sealed receptacle, an electrolyte in said retainable and because asolution containing sodium ceptacle, electrode means in said receptacle for iodide has a conductivity that gradually apcontacting said electrolyte and for conducting proaches a limit at approximately 80 C. Since current therefrom in accordance with the area the solution is hermetically sealed in a container l5 of said electrode means in contact with said elecadapted to withstand appreciable pressures, the trolyte, said electrolyte comprising a 95% condevice is capable of operation at temperatures centration of ethanol containing 0.3 N sodium in excess of 80 C., the boiling point at atmosiodide.

pheric pressure. With a switch of the general 3. A liquid level switch effective over a temproportions shown in Figs. 1 and 2, and having 20 perature range of 65 C. to +80 C. comprising an outside diameter of the order of one inch, a receptacle filled with an electrolyte save for total current flow through the switch amounted an air bubble movable along the top of said reto over 100 milliamperes, and the differential be- Oeptfcle according to the orientation of said retween opposite electrodes reached as high as 50 ceptacle, at least one electrode adjacent to said milliamperes, 25 top and having an exposed surface contacting Since many changes could bemade in the above *.Sd electrolyte t0 provide current flow at p0rconstruction and many apparently widely diftions free of said bubble, said electrolyte comferent embodiments of this invention could be prisms an azeotropic mixture of ethanol and made without departing from the scope thereof, water rendered conductive by the addition of it 1s intended that al1 matter contained in the 3o sodium iodide at Concentrations in the range of above description or shown in the accompanying 0.1 N to 1.5 N, said mixture maintaining uniform drawing shan be interpreted as iuustrative and proportions of ethanol and water during local notinalimiting sense. heating and evaporation at said electrode.

What is claimed is: 1. A liquid level switch comprising a closed 35 ELWOOD J. WILSON, Jn.

CERTIFICATE oF CORRECTION. Patent No. 2,587,515. october 25, 19h5.

' Eiwoon J. wisoN, JE.

It is hereby certified that error appears lin' the printed specification of the above numbered patent requiring correction as follows: Page 5, second column, line 6, claim l, for the word uiodinen read -iodide; -and. that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.-

Signedvand sealed this 29th day of January, A. D. 1911.6.

Leslie Frazer (Seal) First Assistant Commissioner of` Patents. 

